Mattress construction



Maxch 12, 1940- w. G. SCHUBERT MATTRESS CONSTRUCTION Filed June 22, 1959 2 Sheets-Sheet 1 1 MATTORNEYI,

March 12, 1940. w sc 2,193,410

MATTRESS CONSTRUCTION Filed June 22, 1939 2 Sheets-Sheet 2 Patented Mar. 12, 1940 I MATTRESS CONSTRUCTION I Wilfred G. Schubert, Cincinnati, Ohio, asslgnor to The Stearns & Foster Company, Lockland, Ohio.

a corporation of Ohio Application June 22, 1939, Serial No. 280,619

7 Claims.

This invention relates to mattresses and improvements in the construction of them. The

Y invention, generally speaking, is directed to an inner spring type of mattress and particularly to the cushioning or resilient material which is located upon the inner spring.

In the conventional inner spring type of mattress cotton batting, wadding, felt or similar fibrous cushioning material is provided intermediate the outer mattress-covering and the inner spring. More recently mattresses have been made entirely of porous cellular rubber and the inner springs and celiulosic padding have been omitted. One of the primary objectives of this invention has been to combine such rubber cushioning with cellulosic cushioning so that the advantages of the rubber and the cellulosic cushioning are obtained without the disadvantages.

attendant the use of either of them, alone.

Porous cellular rubber is very resilient, in fact so much so that to some people it is uncomfortable to sleep upon. In addition, rubber gives oil a characteristic and somewhat objectionable odor which is noticeable even through the outer mattress covering. Mattresses made entirely of rubber are expensive to construct, at present considerably more so than mattresses of the conventional inner spring type.

On the other hand, cellulosic cushioning, while being less resilient than rubber cushioning, possesses a stability which is very desirable in mattress construction, particularly when the mattresses are to be slept upon by persons of relatively heavy weight. This cushioning is devoid {of any odor and it is inexpensive to use.

This invention is directed to the problem of utilizing the relatively stable, inexpensive and odorless cellulosic padding, in conjunction with the relatively resilient but odorous and relatively expensive rubber, to obtain an improvement in the sleeping quality of the mattress with a reduction in the cost and with an elimination of the noticeable rubber odor.

Briefly, the present invention contemplates mattresses in which a relatively thin layer of porous cellular rubber, for instance, a layer an inch or two in thickness, is supported over an in ner spring on the central or body portion of one or both sleeping surfaces of the mattress. The endwise portions, that is, the portions extending from the crosswise edges of the rubber pad to the ends of the mattress are comprised of cellulosic cushioning. By virtue of this construction, the abdominal portion of the body rests upon the resilient rubber cushioning, while the head and foot portions of the body are supported upon cellulosic material. In this way, the advantages of the rubber are combined with the advantages of the typical mattress cushioning material. No rubber is present at either end of the mattress upon which the head may rest, so that the odor of the rubber becomes unnoticeable. By localizing the use of rubber to the central or abdominal portion of the mattress, the total cost of 0on struction is considerably decreased.

However, the rubber padding and the cellulos padding physically are very dissimilar, and the problem of joining the two in the mattress so that they remain in predetermined relation to one another is a diflicult and complex one. It is requisite, of course, that there be no humps or unevenness along the line at which the rubber and the cellulosic padding coincide. It is also desirable to have the rubber padding anchored firmly both crosswise and longitudinally of the mattress, either to the inner to prevent the rubber pad from shifting about over the surface of the mattress during usage. Because of its porous nature, the rubber tends to tear if it is sewed or stitched.

To overcome these problems, in the mattresses of this invention, the marginal portions of the rubber pad and the cellulosic pad in the crosssprings or to the layer of padding attached thereto, in order wise direction of the mattress are coextensive with one another, and complementary edgewise portions of the respective pads are cut away, so that the upper surfaces of the two pads are flush with one another. In the preferred construction, the coextensive portions of the rubber pad and the cellulosic pad are chamfered relatively to one another; these chamfered edges are overlapped, with the upper surface of the rubber pad and the upper surface of the cellulosic pad,

forming, in the longitudinal directions of the mattress as well as in the crosswise direction, a smooth continuous surface which is devoid of humps or cavities. In place of the chamfered edge lap construction, a double overlap may be employed by grooving the crosswise edge of the rubber pad and forming a complementary edge for insertion within the groove of the adjoining pad member. Then, for physical attachment of the two pads, cement preferably is employed, though stitching or staples may also be used in these arrangements.

One of the primary virtues of the construction is that the joint which is formed is durable, and capable of preventing the cellulosic and rubber pad from'moving relativelytoone another during will not detract from the sleeping comfort of the mattress and, in fact, is entirely unnoticeable to the touch through the outer ticking of the mattress.

The invention further is predicated upon the feature of .uniting fabric flaps to the respective longitudinal edges of the rubber pad by means of adhesive or cement, for instance, typical rubber cement. These fabric flaps are dimensioned to extend beyond theupper and lower faces of the rubber padding. The upper extension of fabric is then stitched either to the side cover ticking or to the surface ticking or, better still, to both. The lower extension of the fabric, at the respective sides of the rubber cushion, is anchored either to the inner springs directly or to a layer of padding which, in turn, may be anchored to the inner springs.

In the preferred construction, the cellulosic cushion is comprised of a layer of cotton wadding, cotton felt, batting or like material, covered at one face or both with a sheet of muslin or similar material. The padding layer and the muslin may be stitched together at regular intervals in order to hold the padding layer to the muslin. For instance, the conventional material known in the industry as Insulo cushion padding is suitable. However, in this description, the term cellulosic padding also is intended to include fibrous padding, such as sisal, hair or hair-like material which may or may not be of cellulosic origin, strictly speaking.

The rubber pad is comprised of a layer of porous spongelike rubber having cellular cavities moulded in one of its faces. This layer, in a typical construction; is approximately 1 inch thick overall with cellular cavities extending to a depth of approximately five-eighths of an inch from the under side of the pad, though pads which are smooth on both faces may be used, if desired. It is preferable to locate the pad upon the mattress so that the smooth side lies adjacent the outer tick, with a layer of cellulosic padding between the lower face of the. pad and the upper face of the inner spring so as to protect the rubber pad from being cut by the springs and also to provide additional stability to this padding layer. If desired a relatively thin layer of batting or wadding or the like also may be installed over the entire surface of the mattress directly beneath the tick.

Further features and advantages of the present invention ago are disclosed in the following detailed description of the preferred embodiment of the invention and in the drawings in which:

Figure 1 'is a side elevation of" a portion of the mattress with part of the construction being shown in cross section to illustrate the relationship of the parts.

Figure 2 is a plan view of the mattress having the ticking broken away to show the relationship of the rubber pad and the cellulosic cushion.

Figure 3 is a fragmentary sectional perspective view showing the longitudinal attachment of the rubber and cellulosic padding therebeneath.

Figure 4 is a fragmentary sectional view, indicated on Figure 1 by line 4-4, taken crosswise of the mattress through the cellulosic padding adjacent an end of the mattress.

Figure 5 is a sectional view taken on the line 5-5 of Figure 2.

Figures 6 and '7 are views similar to Figure 5 showing further modifications of the crosswise joint between the rubber pad and the cellulosic pad.

The mattress illustrated in the drawings is comprised of an inner spring, indicated generally at I, covered over both surfaces respectively, with layers of cellulosic padding 2-2, one for each face of the spring. The inner spring is of the conventional type and includes marginal upper and lower edge wires or helical spring rimming 3.

The cellulosic padding 2, at each face of the inner spring, is made up of a cushion layer 4, covered at both surfaces preferably with sheets of muslin 5-5. It is recommended that the pads 2 be extended over the entire upper-and lower surfaces of the inner spring, with the terminal coils of the spring members in the inner spring resting against the inward sheets of muslin 5. It is also considered to be the best practice to overlap the marginal edges of the pads 2 about the edge wires 3 of the inner spring, and to anchor the overlapped portions relative to the edge wire, either by means of suitable stapling or stitching 6, as indicated in perspective in Figure 3. If desired, layers or strips of burlap may be placed intermediate the terminal coils of the springs and the cellulosic pads, in order that the springs may be prevented from tending to cut into or through the muslin or sheeting, though this precaution is not requisite.

A porous cellular rubber pad or layer of rubber l is placed upon the cellulosic padding 2 intermediate the ends of the assembly, at one or both sides of the mattress. This pad extends across the mattress with its longitudinal edges being substantially flush with the padding overlapping the longitudinal edge wires.

The rubber pad is smooth upon the upper surface and cells or cavities 8 extend into the rubber from the inward surface so as to make this cushion still more resilient. However, the crosswise edges of the pad are spaced inwardly from the ends of the assembly, for instance, 12 to 18 inches or so, the rubber thus being confined to the portion of the mattress upon which the abdomen normally is rested. Cellulosic pads 99 extend from the crosswise edges of the pad of rubber l to the ends of the mattress to complete the sleeping surface. Over the entire assembly the usual ticking or outer covering I0 is provided.

The combined rubber and cellulosic padding layers may be located atone or both surfaces of the inner spring. In the commercial structure, which is illustrated in the drawings, the combined rubber and cellulosic pad layer-is located at only one surface of the inner spring, and the other surface is built up in accordance with the usual mattress construction; this arrangement is employed so that the mattress is reversible to suit the comfort of a particular user. The assembly of the rubber and cellulosic lpadding is therefore described in relation to only one surface of the mattress, and can be duplicated at the other side, if desired.

For constituting a smooth, unbroken crosswise line of transition betweencellulosic padding and rubber padding, the crosswise edges of the rubber pad are chamfered or cut away, as illustrated in Figure 5. This edge construction may be formed by moulding at the time the rubber pad itself is formed, or later as the case may be. The cellulosic padding 9 is comprised of the usual fibrous cotton filler or the like, covered by a layer of fill ' the lines l2.

The crosswise edge of this cellulosic padding layer is formed to complement the chamfered edge of the rubber padding, the layer of muslin being brought over the edge of the cellulosic pad, and the latter being located under the configurated edge of the adjoining rubber cushion.

In other words, the crosswise edges to be adjoined, of both the rubber pad and the cellulosic pad, are configurated so as to be marginally coextensive, while at least the exposed surfaces of the two pads are flush with one another.

One of the virtues of this construction is that the meeting facesof the two pads are of increased area. Cement may be employed for attaching the rubber to the muslin in order that a firm and durable union be obtained. It is not important whether the rubber overlaps the cellulosic padding or whether the cellulosic padding overlaps the rubber, since the line of transition, in either instance, is substantially smooth, even and unnoticeable through the outer ticking II).

In the modification shown in Figure 6, the

crosswise edges of the rubber pad are grooved, to

be of V configuration, as shown. The crosswise edge of the cellulosic pad is formed to an edgewise line suitable for insertion within the groove, the muslin layer I I being folded over the edge to reside adjacent the rubber when the pad is slipped in the groove. This construction essentially constitutes a double chamfer formation of the type previously described. The area of the meeting faces of the cellulosic pad is increased correspondingly.

A half lap formation is employed in the construction shown in Figure 7, the rubber cushion forming a crosswise lip l4 overlying a similar lip I5 formed at the crosswise edge of the cellulosicpadding. In this instance, the muslin II is formed to the contour of the lip on the cellulosic pad and is returned along the lower edge as at l 6, to reside adjacent the layer of muslin 5 on the pad therebeneath.

In place of cement for uniting the layer of muslin of the cellulosic pad to the rubber pad, the coextensive portions may be stitched together at intervals, provided the overlap is sufliciently great so that none of the stitching is located close to the edge of the rubber,,lest the rubber be torn during the normal usage of the mattress.

The muslin of the cellulosic pads 9 adjacent the ends of the inner spring is attached to the muslin 5 of the cellulosic pad 4 so that these pads are anchored in the endwise direction.

Tufts maybe employed to anchor the pads 9 to the inner spring if desired. Tufting at intervals also may extend through the rubber padding to prevent this layer from sagging outwardly when the mattress is overturned. In place of tufting, cement is applied in local areas to hold the rubber ,to the pad beneath it.

For the anchorage of the longitudinal edges of the rubber pad edgewise flaps II are employed one for each edge. These fiaps may be suitable strips of fabric or adhesive ta the latter is ready to use and is very suitable for commercial production. The flaps are cemented to the longitudinal edges of the rubber and extend above the surface of it as at the lip portion l8, and below the surface of it as in the lip portion is illustrated in Figure 3. By the cement attachment of the fabric to the rubber, the 'joint which is obtained is a very strong one, in fact, stronger than the rubber itself.

The lower lip IQ of each flap .is stitched or stapled to the muslin of the cellulosic layer 4 which is anchored to the rim wires 3. The upper and side members 20 and 2| of the ticking are brought together with the upper lips 18 respec-.

tively of the-flaps "and all are stitched together as indicated by the stitching 23. This assembly may be housed within piping 24 to form a finished longitudinal edge structure.

The muslin cover I! of the cellulosic pads.at the ends of the mattresslikewise may be caught with the upper and side tickingmembers and stitched thereto as shown in Figure 4, with the piping 24 concealing the seaming of the muslin and the upper and side tick members.

' Having described my invention I claim: l. A mattress comprising an inner spring, a layer of material disposed upon said spring, a porous cellular pad comprised of rubber supported by said layer of material and having its edges terminating inwardly of the ends of the spring, cellulosic padding extending from the edges of said rubber pad respectively to the ends of the spring, means providing jointed connection of the cellulosic padding with the rubber pad to maintain the outer surfacesof the cellulosic padding and the rubber pad flush with one another and provide a smooth, unbroken sleeping surface, and an outer ticking covering said assembly.

2. A mattress comprising an inner spring, a layer of material disposed upon said spring, a layer of porous cellular rubber padding supported by said layer of material, intermediate the ends of the inner spring, with the crosswise edges of the rubber padding spaced inwardly from the ends of the spring, cellulosic padding supported by the inner spring and extending from the crosswise edges of the rubber padding to the ends of the spring, means providing jointed connection of the respective crosswise edges of the cellulosic padding and the adjacent edges of the rubber padding for maintaining the outer surfaces of the rubber and cellulosic padding in fiushrelationship, and means for connecting the longitudinal edges of the rubber padding and the inner spring, the rubber padding constituting the portion of the mattress upon which the body rests, and the cellulosic padding constituting the portions normally supporting the head and feet and being devoid of the odor of the rubber padding.

3. A mattress which is comprised of an inner spring, a layer of material disposed upon said inner spring, a porous cellular layer of rubber supported by the layer of material and having its crosswise edges terminating inwardly from 4. A mattress comprising an inner spring, a

porous cellular rubber padding layer mounted across a face of the inner spring and spaced inwardly from the ends thereof-with the edges of the pad in crosswise direction of the mattress being chamfered, cellulosic padding extending from the chamfered edges of the rubber pad to the ends of the spring and adjoining the chamfered edges of the rubber pad in overlapping relationship, with the surface of the rubber pad and the surfaces of the endwise cellulosic padding being substantially flush with one another, presenting a substantially smooth, unbroken, mattress sleeping surface.

5. A mattress comprised of an inner spring, cellulosic padding anchored to said inner spring and extending over a surface thereof, a layer of porous cellular rubber padding of substantial thickness extending across the inner spring, with the longitudinal edges of the rubber padding being substantially flush with the longitudinal edges of the inner spring and with the crosswise edges of the rubber padding being spaced inwardly from the respective ends of the inner spring flap members adhesively united to the longitudinal edges of the rubber padding, and extending into anchorage with the said cellulosic padding, and cellulosic padding extending from the crosswise edges of the rubber padding to the ends of the inner spring, the latter said cellulosic padding constituting the portions of the mattress assembly upon which the head and foot portions of the body are rested, and means providing connection of the rubber padding and the latter said cellulosic padding.

6. A mattress comprised of an inner spring, cellulosic padding anchored to said inner spring and extending over the surface thereof, a layer of porous cellular rubber padding of substantial thickness extending across the inner spring, with its longitudinal edges being substantially flush with the longitudinal edges of the inner spring and with its crosswise edges being spaced inwardly from the respective ends of the inner spring, flap members adhesively united to the longitudinal edges of the rubber padding, and

extending beyond the surface thereof into anchorage with the said cellulosic padding, and cellulosic padding extending from the said crosswise edges of the rubber padding to the ends of the inner spring, the latter said cellulosic padding constituting the portions of the mattress assembly upon which the head and foot portions of the body are rested, the rubber padding and the latter said cellulosic padding in the crosswise direction of the mattress being marginally coextensive and constituting an overlap joint, with the sleeping surface of the rubber pad being flush with the surfaces of the adjoining cellulosic padding.

7. A mattress comprising an innerlspring, a layer of material disposed upon said spring, a layer of porous cellular rubber padding supported by said layer of material and terminating inwardly from one end of the inner spring, cellulosic padding supported by the inner spring and extending from the crosswise edge of the rubber padding to the end of the spring, means providing jointed connection of the crosswise edge of the cellulosic padding and the adjacent edge of the rubber padding for maintaining the outer surfaces of the rubber and-cellulosic padding in flush relationship, and'means for anshoring the rubber padding to the inner spring, the rubber padding constituting the portion of the mattress upon which the body rests, and the cellulosic padding constituting the portion normally supporting the head and being devoid of the odor of the rubber padding.

WILFRED G. SCHUBERT. 

